Photochromic multifocal lenses

ABSTRACT

A high index of refraction, low softening point, low expansion segment glass is fused into a countersunk photochromic glass blank of lower index of refraction. The high index of refraction segment is primarily composed of SiO 2 , B 2  O 3 , and PbO with lesser amounts of other oxides.

This is a division of application Ser. No. 414,475 filed Nov. 9, 1973, now U.S. Pat. No. 3,915,723 issued Oct. 28, 1975, which is a continuation-in-part of application Ser. No. 333,835 filed Feb. 20, 1973, now U.S. Pat. No. 3,801,336, issued Apr. 2, 1974.

BACKGROUND OF THE INVENTION

1. Field of the Invention

Fused glass multifocal lenses with particular reference to multifocal lenses having major portions formed of photochromic glass and glass segment portions of lower refractive index fused thereto.

2. Description of the Prior Art

Multifocal lenses having segment portions of high refractive index glass fused to major portions of relatively low refractive index glass are common in the art as evidenced by U.S. Pat. Nos. 2,755,706 and 2,958,162. Glasses used for the segment and major portions of such lenses, i.e. having compatible coefficients of expansion and softening temperatures, are readly available in colors or clear.

Since, however, these segment glasses do not provide a compatible expansion fit and do not have softening temperatures low enough to prevent impairment of the photo-response of known photochromic glass major portions after fusion, the manufacture of photosensitive multifocal lenses has been restricted either to those of one-piece construction of the type shown in U.S. Pat. Nos. 2,410,145 and 2,890,551, for example, or of the cemented type wherein the segments are cemented into countersinks of of major portions of the lenses or the alternative of a photochromic overlay.

Cemented glass multifocal lenses are currently becoming obsolete in view of their not being able to withstand air-toughening temperatures or ion-exchange processing now used and/or contemplated for future use in the finishing of lenses for customer wearing purposes.

In the light of occupational safety and health regulations now requiring all glass lenses to be toughened either by air hardening or ion exchange process before wearing, glass photosensitive multifocal lenses capable of withstanding the required toughening processes have, heretofore, become extremely difficult if not impossible to produce. The cemented type tends to delaminate and/or otherwise become interfacially defective, while, on the other hand, impairment of the required or desired photoresponse characteristics of photochromic lens major portions and interfacial defects result from attempts to fuse segment portions of conventional high refractive index glasses to the photochromic major portions.

A principle objective of the present invention is to provide a novel high refractive index multifocal lens segment glass having a coefficient of expansion which is compatible with currently available photochromic relatively low refractive index lens major portion glass, the high index segment glass having a softening temperature which is low enough to prevent impairment of photoresponse of the photochromic major portion glass during the operation of thermally sealing (i.e. fusing) the segment glass to the photochromic major portion glass.

Another object of the invention is to provide a family of high refractive index glasses suitable for thermal sealing to currently available low refractive index photochromic glasses without impairment of the photoresponse of the latter glasses and to provide improved multifocal lenses incorporating these high and low refractive index glasses.

The invention will be more readily understood from the following detailed description taken in conjunction with the accompanying drawings.

IN THE DRAWINGS

FIG. 1 is a front elevational view of a fused multifocal lens of a type which is pertinent to this invention;

FIG. 2 is a view in cross-section, of a segment component useful in the manufacture of lenses of the type illustrated in FIG. 1;

FIG. 3 is a cross-sectional view of an assembly of major and segment portions of glass from which a multifocal lens of the type illustrated in FIG. 1 may be formed;

FIG. 4 is a front elevational view of another type of fused multifocal lens:

FIG. 5 is a frontal view of a segment component useful in the manufacture of lenses of the type illustrated in FIG. 4; and

FIG. 6 is a view, in cross-section, of an assembly of major and segment portions of glass from which a multifocal lens of the type illustrated in FIG. 4 may be formed.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Examples of photochromic glasses known and used for ophthalmic lenses are given in U.S. Pat. Nos. 3,208,860 and 3,449,103.

The disclosure of the first-mentioned patent concerns inorganic silicate glasses containing submicroscopic crystals of a silver salt, e.g. silver chloride, silver bromide, silver iodide, all of which become darker in color when the glass is subjected to actinic radiation. The glasses regain their original color when the radiation is removed.

The latter U.S. Pat. No. 3,449,103 discloses still another photochromic or phototropic glass useful for lenses or the like.

While various types of photochromic glass may be used for the present invention, a photochromic glass having the following analysis may be considered as typical of the type suitable for use in conjunction with improved segment glasses of the present invention:

                  TABLE I                                                          ______________________________________                                         Oxide            Weight Percent                                                ______________________________________                                         SiO.sub.2                  57.3                                                Mixed Al.sub.2 O.sub.3     10.8                                                   Fe.sub.2 O.sub.3                                                            BaO                        8.17                                                Na.sub.2 O                 6.23                                                B.sub.2 O.sub.3            17.54                                               Traces of AgH                                                                  ______________________________________                                    

Glasses of the aforementioned type are manufactured by Corning Glass Works of Corning, New York, and sold under the trade names Photogray and Photosun. These are exemplary of photochromic glasses to which the present invention is especially applicable and they are currently identified by Corning Glass Works by order numbers 8097 and 8098 respectively.

These glasses may or may not be heat treated to produce or enhance their photochromic properties prior to their use in accordance with the invention. The fusion of segment glasses to heat treated (i.e. nucleated) photochromic type glasses (e.g. those having been subjected to heat treating temperatures of from 500° to 800°c for periods of from as little as 1 minute to 16 or more hours) has been found to produce negligible, if any, adverse affect upon their photochromic properties. In the case of photochromic type glasses which have not been heat treated (i.e. unnucleated glasses) the heat used for segment fusion according to this invention has been found to develop and/or enhance their photochromic properties and obviate the need for separate heat treatment.

In producing fusion with little or no distorted interface between a low refractive index major portion and a high refractive index segment, the low refractive index glass should have a higher viscosity at the fusion temperature than the segment. Preferably, the low refractive index photochromic major portion would have a refractive index of from 1.50 to 1.55 and the refractive index of the segment glass would be within the range of from 1.59 to 1.70. At fusing temperature, the viscosity of the high refractive segment glass should be lower by about three orders of magnitude than the viscosity of the low refractive index major portion glass. It has been found that, under these conditions, fusion stress of the fused glasses is usually less than 30 kg/cm².

The high refractive index segment glass is formed generally of silicon dioxide, boron oxide and lead oxide, with minor amounts of other oxides. Ranges of ingredients useful for forming this high refractive index segment glass, according to the invention, are given in the following table:

                  TABLE II                                                         ______________________________________                                                        Weight Percent                                                  SiO.sub.2        16 - 36                                                       B.sub.2 O.sub.3  14 - 33                                                       Al.sub.2 O.sub.3  8.5 - 10.5                                                   ZnO              4.2 - 5.4                                                     BaO              1.9 - 2.5                                                     As.sub.2 O.sub.3 0.25 - 0.35                                                   PbO              27 - 36                                                       Sb.sub.2 O.sub.3 1.4 - 2.0                                                     K.sub.2 O        0 - 2                                                         Na.sub.2 O       0 - 1                                                         TiO.sub.2        0 - 5                                                         La.sub.2 O.sub.3 0 - 6                                                         ______________________________________                                    

Generally the high index segment glass has a composition within the ranges set forth in table IIA as follows:

                  TABLE II A                                                       ______________________________________                                                        Weight Percent                                                  SiO.sub.2        20 - 32                                                       B.sub.2 O.sub.3  17 - 30                                                       Al.sub.2 O.sub.3  9 - 10                                                       ZnO              4.2 - 5.4                                                     BaO              1.9 - 2.5                                                     As.sub.2 O.sub.3 0.25 - 0.35                                                   PbO              27 - 36                                                       Sb.sub.2 O.sub.3 1.59 - 1.9                                                    K.sub.2 O        0 - 2                                                         Na.sub.2 O       0 - 1                                                         TiO.sub.2        0 - 4                                                         La.sub.2 O.sub.3 0 - 6                                                         ______________________________________                                    

The preferred high refractive index segment glasses are those with a composition as defined in table IIB as follows:

                  TABLE II B                                                       ______________________________________                                                        Weight Percent                                                  SiO.sub.2        20 - 32                                                       B.sub.2 O.sub.3  17 - 30                                                       Al.sub.2 O.sub.3  9 - 10                                                       ZnO              4.6 - 5.0                                                     BaO              2.1 - 2.3                                                     As.sub.2 O.sub.3 0.25 - 0.35                                                   PbO              30 - 33                                                       Sb.sub.2 O.sub.3 1.5 - 1.9                                                     TiO.sub.2          2 - 3.5                                                     La.sub.2 O.sub.3 2 - 6                                                         ______________________________________                                    

The high refractive index segment glass is prepared by mixing its ingredients for about 5 minutes, heating the mixture to melting temperature, fining the resulting glass of the melt and then casting the fined glass into the form of a flat sheet or a multiplicity of lens segments. After annealing and cooling, the cast segments or segments cut from a cast sheet of the resulting glass may then be ground and polished to the size and shape desired.

A preferred composition for the high refractive index segment glass is as follows:

                  EXAMPLE I                                                        ______________________________________                                                        Weight Percent                                                  SiO.sub.2        20.50                                                         B.sub.2 O.sub.3  21.90                                                         Al.sub.2 O.sub.3 9.60                                                          ZnO              4.80                                                          BaO              2.20                                                          As.sub.2 O.sub.3 0.30                                                          PbO              31.50                                                         Sb.sub.2 O.sub.3 1.7                                                           TiO.sub.2        2.75                                                          La.sub.2 O.sub.3 4.75                                                          ______________________________________                                    

A batch of glass formed of the foregoing composition in the proportions of ingredients given in the following Example IA will have an index of refraction of approximately N₄₈₆ =1.6706, N₅₈₉ =1.6584, N₆₅₆ =1.6537, where 486, 589 and 656 are wavelengths of light in millimicrons. Its strain point will be approximately 893°F, anneal point approximately 944, and fiber softening point 1151°F.

                  EXAMPLE IA                                                       ______________________________________                                         Composition       Grams                                                        ______________________________________                                         SiO.sub.2 (Potter's Flint)                                                                       922.50                                                       B.sub.2 O.sub.3 (Fused)                                                                          985.50                                                       Al(OH).sub.3      660.60                                                       ZnO               216.00                                                       BaCO.sub.3        127.35                                                       As.sub.2 O.sub.3  13.50                                                        PbO               1417.50                                                      Sb.sub.2 O.sub.3  76.50                                                        TiO.sub.2         123.75                                                       La.sub.2 O.sub.3  213.75                                                       Total             4756.95     grams                                            ______________________________________                                    

The glass of this composition (Example IA) was formed by mixing all of its ingredients together and melting the mixture in a platinum crucible. The crucible was placed in a furnace wherein its temperature was raised over a period of about four hours from room temperature to a temperature between 2600° and 2650°F to melt the ingredients. The melt was maintained, for the purpose of fining, at a temperature of about 2600°F for a period of about 16 hours. A temperature within the range of from 2300° to 2650°F, held for a period of from 1 to 16 hours, will produce similar results.

Following the fining cycle, the furnace temperature was gradually lowered to approximately 2000°F and the melt was stirred for approximately four hours at 2000°F.

After stirring, the glass was cast at approximately the same 2000°F temperature onto an iron plate, annealed and cooled and then cut, ground and polished into a multiplicity of pieces each of the configuration desired for use as a segment or as a portion of a segment adaptable to fusion to a photochromic major piece of glass for the making of a fused multifocal lens.

Referring more particularly to the drawings, there is illustrated in FIG. 1 a fused multifocal lens 10 having a major portion 12 formed of a photochromic glass, e.g. of the composition set forth hereinabove under Table I and a segment 14 of a relatively high refractive index glass, e.g. of the composition set forth in Example IA.

In the making of multifocal lens 10, segment 14 (FIG. 2), after having been cast or cut from the aforementioned high refractive index glass, is customarily ground and optically polished on a side 16 to a spherical curvature corresponding to the curvature of a countersink 18 which is also ground and polished into the major piece 12 of lens 10. Surface 16 of segment 14 may be formed to a curvature of slightly shorter radius than that of countersink 18 for purposes of initially making point contact with countersink 18 and thereby expressing air and gases radially outwardly of countersink 18 as segment 14 is caused to gradually assume the countersink shape when heated for fusion thereto, e.g. at a temperature of approximately 1150°F and held at the fusing temperature for a period of time of approximately from 7 to 10 minutes. Following the fusion of segment 14 to countersink 18 of major piece 12, grinding and polishing of the resultant assembly shown in FIG. 3 along lines 20 and 21, for example, will complete opposite sides of the fused multifocal lens 10. Those interested in greater details of this technique for forming a fused multifocal lens may refer to U.S. Pat. No. 2,958,162.

While FIGS. 1-3 illustrate the making of a multifocal lens having a segment 14 of circular configuration, it should be understood that the present invention is equally applicable to the making of multifocal lenses having segments of different shapes, e.g. of the type shown in FIG. 4. This lens 10' (FIG. 4) is of the type having a segment 14' with a flat or straight upper edge 22. Such a multifocal lens 10' is commonly referred to in the art as a "cutoff" style fused multifocal. Its upper edge 22 may be arcuate with a slightly upwardly directed curvature which blends smoothly into the curvature of the lower portion of the segment or acutely joins the depending curvature of the segment.

In the manufacture of the cutoff fused multifocal, its segment 14' (FIG. 5) is formed of two pieces 24 and 26 each cut, ground and polished to the general configuration shown in FIGS. 5 and 6. Piece 24 has the aforementioned straight upper edge 22. Piece 26 is formed of a photochromic glass, preferably identical to the glass used for major piece 12' and is edge fused, e.g. at a temperature of approximately 1150°F, to piece 24 of segment 14'. The two pieces 24 and 26 are then provided with a ground and polished face 16' and, as a unit, fused into countersink 18' of major piece 12.

Multifocal lens 10' is formed by grinding and polishing the fused assembly of segment 14' and major piece 12' to a finished shape and size, e.g. along lines 20' and 21'. Those interested in greater details of the forming of cutoff style fused multifocal lenses may refer to U.S. Pat. No. 1,899,777, for example. In the manufacture of the two piece fused segment 14' of FIG. 5 a preferred composition for the glass portion 24 is that listed under column 9 of Table III which follows.

                                      TABLE III                                    __________________________________________________________________________     Oxide 2      3      4      5      6      7      8      9                       __________________________________________________________________________     SiO.sub.2                                                                            20.00  24.00  28.00  32.00  26.00  24.00  21.00  20.00                   B.sub.2 O.sub.3                                                                      29.90  25.90  21.90  17.90  21.90  21.90  21.90  21.90                   Al.sub.2 O.sub.3                                                                     9.60   9.60   9.60   9.60   9.60   9.60   9.60   9.60                    ZnO   4.80   4.80   4.80   4.80   4.80   4.80   4.80   4.80                    BaO   2.20   2.20   2.20   2.20   2.20   2.20   2.20   2.20                    As.sub.2 O.sub.3                                                                     0.30   0.30   0.30   0.30   0.30   0.30   0.30   0.30                    PbO   31.50  31.50  31.50  31.50  31.50  31.50  31.50  31.50                   Sb.sub.2 O.sub.3                                                                     1.70   1.70   1.70   1.70   1.70   1.70   1.70   1.70                    TiO.sub.2                                                                            --     --     --     --     2.00   2.00   3.00   3.00                    La.sub.2 O.sub.3                                                                     --     --     --     --     --     2.00   4.00   5.00                    N.sub.D                                                                              1.6153 1.6172 1.6136 1.6109 1.6311 1.6430 1.6572 1.6642                  S.T.°F                                                                        1099   1138   1161   1198   1149   1160   1158   1166                    *α × 10.sup.7                                                            52     51     47     45     49     54     51     55                      __________________________________________________________________________      *α = coefficient of expansion                                      

                  TABLE III A                                                      ______________________________________                                         Oxide  10       11       12     13     14                                      ______________________________________                                         SiO.sub.2                                                                             32       28.45    18     23     20.5                                    B.sub.2 O.sub.3                                                                       16.4     21.9     31.9   21.9   21.9                                    Al.sub.2 O.sub.3                                                                      9.0      10.1     9.6    9.6    9.6                                     ZnO    5.2      4.2      4.8    4.8    4.8                                     BaO    2.0      2.5      2.2    2.2    2.2                                     As.sub.2 O.sub.3                                                                      .35      .25      .3     .3     .3                                      PbO    33.0     27.1     31.5   31.5   31.5                                    Sb.sub.2 O.sub.3                                                                      1.5      1.9      1.7    1.7    1.7                                     TiO.sub.2                                                                             0.55     2.0      --     5      2.75                                    La.sub.2 O.sub.3                                                                      --       --       --     --     4.75                                    K.sub.2 O                                                                             --       1.1      --     --     --                                      Na.sub.2 O                                                                            --       0.5      --     --     --                                      ______________________________________                                    

The above glasses have an index of refraction, strain point (S.T.°F) and coefficient of expansion substantially corresponding to those of EXAMPLE I and examples 2-9 of Table III. These glasses are suitable for forming multifocal lens segments according to the present invention.

Following the procedure outlined above relative to Example I, a series of high refractive index glasses may be manufactured which have compatible expansion coefficients with conventional, commercially available, relatively low refractive index photochromic glasses. The series of eleven high refractive index glasses illustrated in Tables III and IIIA each have a softening temperature low enough to prevent impairment of the photoresponse characteristics of photochromic glasses used in the fused assembly of the segment and major piece in each case of a multifocal lens manufacturing procedure. 

I claim:
 1. A multifocal lens comprising:a major piece of low refractive index photochromic glass; a segment of relatively high refractive index nonphotochromic glass fused to said major piece, said non-photochromic glass consisting essentially of the following ingredients in the range of weight percent:

    SiO.sub.2        16 - 36                                                       B.sub.2 O.sub.3  14 - 33                                                       Al.sub.2 O.sub.3  8.5 - 10.5                                                   ZnO              4.2 - 5.4                                                     BaO              1.9 - 2.5                                                     As.sub.2 O.sub.3 0.25 - 0.35                                                   PbO              27 - 36                                                       Sb.sub.2 O.sub.3 1.4 - 2.0                                                     K.sub.2 O        0 - 2                                                         Na.sub.2 O       0 - 1                                                         TiO.sub.2        0 - 5                                                         La.sub.2 O.sub.3  0 -
 6.                                                  


2. A multifocal lens according to claim 1 wherein said non-photochromic glass consists essentially of the following ingredients in the range of weight percent:

    SiO.sub.2        20 - 32                                                       B.sub.2 O.sub.3  17 - 30                                                       Al.sub.2 O.sub.3  9 - 10                                                       ZnO              4.2 - 5.4                                                     BaO              1.9 - 2.5                                                     As.sub.2 O.sub.3 0.25 - 0.35                                                   PbO              27 - 36                                                       Sb.sub.2 O.sub.3 1.59 - 1.9                                                    TiO.sub.2        0 - 4                                                         La.sub.2 O.sub.3 0 - 6                                                         K.sub.2 O        0 - 2                                                         Na.sub.2 O        0 -
 1.                                                  


3. A multifocal lens according to claim 1 wherein said non-photochromic glass consists essentially of the following ingredients in the range of weight percent:

    SiO.sub.2        20 - 32                                                       B.sub.2 O.sub.3  17 - 30                                                       Al.sub.2 O.sub.3  9 - 10                                                       ZnO              4.6 - 5.0                                                     BaO              2.1 - 2.3                                                     As.sub.2 O.sub.3 0.25 - 0.35                                                   PbO              30 - 33                                                       Sb.sub.2 O.sub.3 1.5 - 1.9                                                     TiO.sub.2          2 - 3.5                                                     La.sub.2 O.sub.3    2 - 5.5.                                              


4. A multifocal lens according to claim 3 wherein said major piece of lower refractive index photochromic glass comprises a silicate glass body having in at least a portion thereof microcrystals of at least one silver halide selected from the group consisting of silver chloride, silver bromide, and silver iodide, the concentration of said crystals in said portion being at least 0.005% by volume.
 5. A multifocal lens according to claim 1 wherein said major piece of lower refractive index photochromic glass comprises a silicate glass body having in at least a portion thereof microcrystals of at least one silver halide selected from the group consisting of silver chloride, silver bromide, and silver iodide, the concentration of said crystals in said portion being at least 0.005% by volume.
 6. A multifocal lens according to claim 1 wherein said major piece is formed of Photogray glass.
 7. A multifocal lens according to claim 6 wherein said segment glass consists essentially of the following ingredients by weight percent:

    SiO.sub.2        20.5                                                          B.sub.2 O.sub.3  21.9                                                          Al.sub.2 O.sub.3 9.6                                                           ZnO              4.8                                                           BaO              2.2                                                           As.sub.2 O.sub.3 .3                                                            PbO              31.5                                                          Sb.sub.2 O.sub.3 1.7                                                           TiO.sub.2        2.75                                                          La.sub.2 O.sub.3 4.75.                                                    


8. A multifocal lens according to claim 1 wherein said major piece is formed of Photosun glass.
 9. A multifocal lens according to claim 8 wherein said segment glass consists essentially of the following ingredients by weight percent:

    SiO.sub.2        20.5                                                          B.sub.2 O.sub.3  21.9                                                          Al.sub.2 O.sub.3 9.6                                                           ZnO              4.8                                                           BaO              2.2                                                           As.sub.2 O.sub.3 .3                                                            PbO              31.5                                                          Sb.sub.2 O.sub.3 1.7                                                           TiO.sub.2        2.75                                                          La.sub.2 O.sub.3 4.75.                                                     